# Fraunhofer develops lifecycle model to calculate battery recycling costs

- Published: 2026-11-06 14:18 UTC
- Section: Power & Energy › Batteries
- Tags: battery recycling model, Fraunhofer FFB, lithium-ion recycling cost, Safeloop consortium, battery shredding impact
- URL: https://realtech.media/news/rt-e4b44f69af1be0e2108b5b10_fraunhofer_develops_lifecycle/

**A new simulation tool tracks material flows and operational costs across the battery recycling chain to evaluate processing methods before scaling.**

![Fraunhofer develops lifecycle model to calculate battery recycling costs](https://sgzwpqqelzmajkcubgkl.supabase.co/storage/v1/object/public/rt-media/2026/11/4688b1a6e7036cb8.webp)
*Interesting Engineering*

The Fraunhofer Research Institution for Battery Cell Production FFB has developed a lifecycle modeling tool designed to help recyclers assess process costs and carbon emissions before altering physical processing lines, according to Interesting Engineering [1]. The software framework emerged from work within the European Union's Safeloop research consortium, which reported an average economic loss of €1.90 per kilogram of processed lithium-ion battery pack under current European market conditions [1]. Hazardous logistics, manual pack dismantling, and variations in material yield were identified as the primary drivers of negative operational margins.

## Tracking material streams

Fraunhofer's Modular Lifecycle Tool models consecutive processing steps using a dedicated database of industrial technologies and separation techniques [1]. Mechanical pre-treatment, particularly cell shredding, significantly alters material downstream: distinct cutting mechanisms change particle size distributions and purity, directly altering the chemical effort and energy needed during hydrometallurgical or mechanical separation [1]. The software links these physical material balances directly to capital expenditure and operational costs across the process flow [1].

## Economic and emissions optimization

Users can configure variables including regional electricity generation mixes, local labor rates, and anticipated facility utilization rates to estimate facility balance sheets [1]. In addition to disposal fees and operational energy requirements, the system accounts for revenue derived from varying purity grades of recovered raw materials [1]. Fraunhofer developed the model alongside industrial engineering, consulting, and recycling partners, with plans to expand the database with additional cell chemistries and regional regulatory constraints [1].

## Sources

1. [Interesting Engineering](https://interestingengineering.com/energy/shredding-affects-battery-material)

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Source: RealTech, realtech.media — https://realtech.media/news/rt-e4b44f69af1be0e2108b5b10_fraunhofer_develops_lifecycle/